Methods of installing interlocking  panel siding and components thereof

ABSTRACT

A method of installing siding on a structure includes the steps of positioning a starter strip at a base of the structure, mounting the starter strip to the structure, and providing a first panel. The starter strip includes a top edge including a top front edge that extends above a top rear edge. The first panel includes a top edge and a bottom edge. The method further includes the step of positioning the bottom edge of the first panel atop the top edge of the starter strip such that a bottom rear edge and a bottom middle edge of the first panel abut a top front edge and a top rear edge, respectively, of the starter strip. The method also includes the step of mounting the first panel to the structure.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. application Ser. No.13/757,729 filed Feb. 1, 2013, which claims the benefit of priority toU.S. Provisional Application No. 61/594,312 filed Feb. 2, 2012, theentireties of each being incorporated herein by reference.

BACKGROUND OF THE INVENTION

The present subject matter relates generally to interlocking siding.More specifically, the present invention relates to an interlockingsiding design that provides an external profile though which there areno perforations exposed after installation.

Siding provides an exterior barrier for walls and surfaces in order toprotect the under layers from the effects of weather and moisture.Siding can also contribute to the aesthetic value of a house orstructure, by adding a tasteful color or texture to the surface.Aesthetic value also can affect the property value of a structure orbuilding, so the appearance of the siding is important. Siding isusually affixed to the outside of a building in panels in an overlappingassembly. Since the siding is traditionally applied in segments, itallows for the expansion and contraction of the building materials thatis caused by various temperatures and humidity. Siding can be composedof many different materials including but not limited to wood, vinyl,metal, cement, or plastic.

Certain kinds of siding can be very labor intensive to manufacture andinstall. Some siding is made of expensive materials, which increases thetotal cost of the installation and purchase of the siding. Installingsiding can be labor intensive because it must be installed in such a waythat seals the outside layer from the elements. Also, siding is onlytypically installed during moderate weather, thus limiting thepossibility of installation in some regions with harsh winters.

During installation, constant attention must be given to the distance ofoverlap of the siding segments, and the placement, to make sure thesegments are appropriately spaced. The placement of the siding isimportant to create a uniform pattern on the outer surface thus givingthe attractive aesthetic appearance in addition to the functionalbarrier.

Accordingly, a need exists for an interlocking siding product and methodas described and claimed herein.

BRIEF SUMMARY OF THE INVENTION

In order to meet the ever growing need to provide an interlocking sidingthat is easy to assemble, install and provides an effective barrier andis aesthetically appealing, the present subject matter discloses asiding with a unique structure. The siding panel includes an indicia fora fastener placement combined with a unique mating potion geometry. Thetop edge of the siding has a front face for facing outside towards theelements and a rear face for facing the internal structure. The panelincludes a top front edge that extends above the top rear edge. Thelower edge of the panel includes three sections adapted for mating tothe top edge of an adjacent panel. The front face of the lower edgeextends the lowest, the middle section is recessed, and the rear sectionfalls between the lowest extension and the recessed portion. A barriermay be formed using identical panels, making installation easy andmaintenance free.

When two or more panels are mated together, they form a barrier tomoisture and other elements. In addition to forming a barrier andkeeping out moisture, the mating mechanism facilitates a mistake-freeassembly. When mated, the front face of the lower edge of an upper panelextends far enough down the front face of the lower panel to cover theindicia for fastener placement located on the front face of the lowerpanel. Therefore when assembled, all of the fasteners used to secure thepanels to the internal structure will be hidden, thus providing aneffective barrier that is visually pleasing. No evidence of thefasteners is left to be seen at an outward view, they will all be hiddenunderneath the overlapping structure of the siding.

The front face of the panel may include a fastener notch. The notchallows the fastener head to sit inside the body of the siding panelrather than protrude beyond the front face. Also, the notch providesindicia for fastener placement such that an installer may be assured thefasteners are properly located to be covered by the adjacent overlappingpanel, thus making it easier to assemble and mistake proof.

In some embodiments the body of the interlocking siding may be made ofrecycled or waste materials. Recycled or waste materials may be costeffective and may also reduce placement in landfills, thus helping theenvironment. For example, the panels may be formed from a single ormultilayer extrusion process. In a multilayer extrusion, the one or moreinner layers may include recycled or waste products, while the outerlayer may be from another material entirely.

In some embodiments the body and rear face of the interlocking sidingpanels may incorporate various patterns and cut outs to decrease theamount of material needed to create the siding. This decreased amount ofmaterial will keep the overall cost of materials down thus making thesiding more affordable. Decreasing the amount of material will alsolessen the weight of the siding and made the product more flexible,which will also make the installation easier.

The method of installation is simple and easy. The first piece to fit atthe base of the structure may be a starter strip. The starter strip hasa flat bottom and a two tier top face for mating with the bottom edge ofthe adjacent panel. After the starter strip is fixed where indicated,the installer may fit the first piece of panel siding onto the starterstrip, the bottom edge of the panel overlapping and interlocking the topedge of the starter strip. Once the first panel is secured to thestarter strip, it may be fastened into the structure where indicated.All subsequent siding panels will fit accordingly in a uniform pattern,using this same method without the need for measuring or use of a spacerto assure consistency, saving time and money. Since all of the sidingpanels are identical, it will be easy to stack the panels togetherwithout needing to differentiate between the panels. The starting stripand unvarying design of siding will allow for a mistake proofinstallation that can be accomplished by a non-expert.

In one example, an interlocking panel system includes: a first panelincluding: a front face including a fastener notch; a rear face; a topedge, wherein the top edge includes a top front edge that extends abovea top rear edge; and a lower edge, wherein the lower edge includes afront edge that extends below a bottom middle edge and a bottom rearedge, further wherein the bottom rear edge extends below the bottommiddle edge; and a second panel including: a front face including afastener notch; a rear face; a top edge, wherein the top edge includes atop front edge that extends above a top rear edge; and a lower edge,wherein the lower edge includes a front edge that extends below a bottommiddle edge and a bottom rear edge, further wherein the bottom rear edgeextends below the bottom middle edge; wherein, when the lower edge ofthe first panel is placed onto the top edge of the second panel, thebottom front edge of the first panel covers the fastener notch of thesecond panel.

The fastener notch may be V shaped, U shaped, or other. In someembodiments, when the lower edge of the first panel is placed onto thetop edge of the second panel, the bottom rear edge of the first panelabuts the top rear edge of the second panel. Similarly, in someembodiments, when the lower edge of the first panel is placed onto thetop edge of the second panel, the bottom middle edge of the first panelabuts the top front edge of the second panel. In some versions, the rearface of the first panel includes a plurality of notches.

In some examples, the interlocking panel system includes a starterstrip, wherein the starter strip includes a front face including afastener notch, a rear face, a top edge wherein the top edge includes atop front edge that extends above a top rear edge, and a base edgeincluding a drip channel, wherein when the lower edge of the secondpanel is placed onto the top edge of the starter strip, the bottom frontedge of the second panel covers the fastener notch of the starter strip.In such an embodiment, when the lower edge of the second panel is placedonto the top edge of the starter strip, the bottom rear edge of thesecond panel abuts the top rear edge of the starter strip and, when thelower edge of the second panel is placed onto the top edge of thestarter strip, the bottom middle edge of the second panel abuts the topfront edge of the starter strip.

In some versions of the interlocking panel system, the first panel is amultilayer construction wherein an inner layer is made from wastematerial.

An advantage of the siding is that it is interlocking.

Another advantage of the siding is it is easy to install

A further advantage of the siding is that it provides a superior barriersurface.

Yet another advantage of the siding is there are no exposed fasteners.

Yet another advantage of the siding is all panels are the same size andconsistent color.

Another advantage of the siding is maintenance free and can be installedin any climate condition.

Additional objects, advantages and novel features of the examples willbe set forth in part in the description which follows, and in part willbecome apparent to those skilled in the art upon examination of thefollowing description and the accompanying drawings or may be learned byproduction or operation of the examples. The objects and advantages ofthe concepts may be realized and attained by means of the methodologies,instrumentalities and combinations particularly pointed out in theappended claims.

BRIEF DESCRIPTION OF THE DRAWINGS

The drawing figures depict one or more implementations in accord withthe present concepts, by way of example only, not by way of limitations.In the figures, like reference numerals refer to the same or similarelements.

FIG. 1 is a side view of an interlocking panel.

FIG. 2 is a side view of an alternative design for an interlockingpanel.

FIG. 3 is a side view of another alternative design for an interlockingpanel.

FIG. 4 is a side view of another alternative design for an interlockingpanel.

FIG. 5 is a side view of another alternative design for an interlockingpanel.

FIG. 6 is a perspective view of a body structure and the finish surfaceof an interlocking panel with multi-lamination.

FIG. 7 is a side view of a starter strip.

FIG. 8 is a side view of an alternative design of a starter strip.

FIG. 9 is a side view of an arrangement of interlocking panels beginningwith the starter strip.

FIG. 10 is a flow chart depicting a method of installing interlockingpanels and starter strip.

FIG. 11 a illustrates an example of V shaped fastener notch that may beused in the interlocking panel shown in FIG. 1.

FIG. 11 b illustrates an example of U shaped fastener notch that may beused in the interlocking panel shown in FIG. 1.

DETAILED DESCRIPTION OF THE INVENTION

FIG. 1 illustrates an example of an interlocking panel 10. As shown inFIG. 1, the interlocking panel includes a body 12 with a front face 14and a rear face 16. The front face 14 is the exterior of the panel 10,which faces the elements, and the rear face 16 will be the interior ofthe panel 10 that faces the wall of the house, stud, sheathing, or otherstructure. The interlocking panel 10 includes a top edge 18 and a loweredge 20. The top edge 18 includes a top front edge 17 that extends abovea top rear edge 19. The configuration of the top edge 18 allows it toconnect to the lower edge 20 when the interlocking panels 10 are stackedadjacently. The lower edge 20 includes a bottom front edge 21 extendingbelow a recessed bottom middle edge 23 and bottom rear edge 25, whichfalls between the bottom front edge 21 and the bottom middle edge 23.Accordingly, the top edge 18 connects by interlocking to the lower edge20 when stacked adjacently.

As shown in FIG. 1, the interlocking panel 10 includes a fastener notch22. The fastener notch 22 provides placement indicia to indicate wherethe fasteners should be placed. When the lower edge 20 is placed on topof a corresponding top edge 18 of another plank, the front face 14 ofthe lower edge 20 will cover the fastener notch 22, thus covering anyevidence of an opening through the panel 10 and preserving the integrityof the barrier. The fastener notch 22 may be routed in a “V” or “U” sothe screw head sits slightly recessed when installed, thereby allowingthe next siding panel 10 to fit together easily without catching on thescrew head. In FIG. 1, the front face of the lower edge 20 extends downa considerable amount, but it is contemplated that this distance may bemore or less as long as it still covers the fastener notch 22 of thenext panel. Examples of fastener notches 22 are shown in FIG. 11 a andFIG. 11 b. However, other fastener notch 22 configurations may be used.

The interlocking panel 10 in FIG. 1 can be made out of many differentmaterials such as wood, plastic, cement, or vinyl. It is suggested thatthe panels be composed of a waste material, or recycled material, tocontribute to conservation and keep costs down. However, it iscontemplated that in other embodiments, the interlocking panel 10 can bemade of any material that is capable of providing a barrier from theelements.

FIG. 2 is an alternative design, very similar to FIG. 1 where the frontface 14 includes a two-tiered profile for aesthetic value. The frontface 14 includes a ridge 27 giving the panel 10 additional texture. InFIG. 2 there is one ridge 27 on the front face 14, but it iscontemplated that in other embodiments, there may be any variation ofridges 27.

FIG. 3 is another design of an interlocking panel. This variationincludes a number of notches 29 on the rear face 16 to conserve theamount of material used to form the panel 10. Also, FIG. 3 contains anoutside layer 24 that may be composed of a more expensive, protective,and aesthetically pleasing material, because the outside layer 24 is athin high quality layer. Then the rest of the body 12 can be composed ofa more cost efficient material.

As shown in FIG. 3, the top edge 18 and lower edge 20 are shapeddifferently than in the example shown in FIG. 1. In FIG. 1 the top edge18 and lower edge 20 include squared corners to rest against each other,whereas in FIG. 3 the top edge 18 and lower edge 20 include aninterlocking shape. Accordingly, the top edge 18 connects byinterlocking to the lower edge 20 when stacked adjacently.

FIG. 4 is yet another variation of an interlocking panel 10 that is verysimilar to FIG. 3. The difference between FIG. 4 and FIG. 3 is the topedge 18 and lower edge 20 profiles.

FIG. 5 is another variation of an interlocking panel 10 in which thereare several cut outs 31 in the body 12, thus saving on materials, andproviding an alternative design. In FIG. 5 there are two cut outs in agenerally oval shape, but the cut outs may be in any shape, and can bein various numbers.

FIG. 6 shows further how in the inner portion of the panel 10 may becomposed of a different material than the outer portion. As discussedpreviously, the inner material may be composed of a waste material,recycled material, or any material that is more economical. Themultilayer panel 10 in FIG. 6 may be formed using a multilayer extrusionprocess.

FIG. 7 shows the starter strip 30 that may be used as the base uponwhich adjacent panels 10 may be stacked. The starter strip 30 contains abody 32 with a front face 34 and a rear face 36, similar to the panel10. The starter strip 30 is smaller than the panels, and is sturdyenough to stabilize the first panel, so the others may follow. Thestarter strip 30 also contains a top edge 38 and a base edge 40. The topedge 38 will connect to the lower edge 20 or one of the first sidingpanels to connect to the starter strip 30. The base edge 40 will beplaced at the base of the house or structure. The base edge 40 alsoprovides a drip channel 42 to prevent water from returning to the innerstructure. The top edge 38 will be shaped to correspond with the designof the panels 10.

FIG. 8 also shows a starter strip 30 that is very similar to FIG. 7. Thebase edge 40 in FIG. 8 is shaped slightly different than the base edge40 in FIG. 7, in that the drip channel 42 is in a different position. Itis understood that the drip channel 42 in the base edge 40 may be in anylocation along the base edge 40, left, right or center.

As further shown in FIGS. 7 and 8, the front face 34 may take on any ofnumerous profiles. Accordingly, it is contemplated that the starterstrip 30 may be any shape, as long as it is adapted to integrate withthe siding panels 10.

FIG. 9 demonstrates how the panels 10 would fit together to form thesiding, starting with the starter strip 30 at the bottom. The starterstrip 30 would sit at the base of the structure, and the panels 10 wouldstack on top of the starter strip 30.

FIG. 10 depicts the method 110 of assembling the siding panels. Thefirst step 120 is mounting the starter strip at the base of thestructure. While the presently preferred method of mounting the starterstrip at the base of the structure is by screwing the starter strip tothe structure, in alternative embodiments, the starter strip may bemounted by nailing, gluing or otherwise securing the starter strip tothe structure. The second step 130 is aligning the first siding panelwith the starter strip and locking them in place. The starter strip andthe siding panel have the corresponding notches that are meant to belocked in place and provide an effective moisture barrier. It is obviouswhen the starter strip and the panel are locked in place because theywill lock or snap in place and fit together easily. The next step 140 isscrewing the first siding panel to the structure. It is apparent toplace the screws in the screw fastener notches that are indicated on thesiding panels. Again, in alternate embodiments, the siding panels may besecured via other means. Once the siding panel is screwed to thestructure, it is secure. The last step 150 is aligning and mounting thesubsequent siding panels. The subsequent siding panels are secured justas the first siding panel was secured to the siding strip. They snap orlock into place and then are screwed to the wall or stud. In instancesin which the panels do not span the width of a structure, the seams ofthe panels should be staggered (not aligned) to help to prevent waterpenetration through the siding to the substructure and butt joints (forexample, 45% angle butt joints) may be provided along the seams, wherebythe siding panels may be glued, caulked or otherwise adhered or sealed.

It should be noted that various changes and modifications to thepresently preferred embodiments described herein will be apparent tothose skilled in the art. Such changes and modifications may be madewithout departing from the spirit and scope of the present invention andwithout diminishing its attendant advantages.

I claim:
 1. A method of installing siding on a structure, comprising the steps of: positioning a starter strip of the siding at a base of the structure, wherein the starter strip includes a top edge comprising a top front edge that extends above a top rear edge; mounting the starter strip to the structure; providing a first panel of the siding including: a top edge, wherein the top edge includes a top front edge that extends above a top rear edge, wherein the top front edge is adjacent to the front face, wherein the top rear edge is adjacent to the rear face, wherein the top front edge is perpendicular to the front face, wherein the top rear edge is perpendicular to the rear face, a bottom edge, wherein the bottom edge includes a bottom front edge that extends below a bottom middle edge and a bottom rear edge, further wherein the bottom rear edge extends below the bottom middle edge, wherein the bottom front edge is adjacent to the front face, wherein the bottom rear edge is adjacent to the rear face, wherein the bottom front edge is perpendicular to the front face, wherein bottom rear edge is perpendicular to the rear face; positioning the bottom edge of the first panel atop the top edge of the starter strip such that the bottom rear edge and the bottom middle edge of the first panel abut the top front edge and the top rear edge, respectively, of the starter strip; and mounting the first panel to the structure.
 2. The method of claim 1, wherein the starter strip includes a front face including a fastener notch that receives fasteners; and wherein the step of positioning the bottom edge of the first panel comprises the step of positioning the bottom edge of the first panel atop the top edge of the starter strip such that the bottom rear edge and the bottom middle edge of the first panel abut the top front edge and the top rear edge, respectively, of the starter strip and the bottom front edge of the first panel covers the fastener notch of the starter strip.
 3. The method of claim 1, wherein the first panel includes a rear face including a plurality of laterally spanning notches.
 4. The method of claim 1, further comprising the steps of: providing a second panel of the siding including: a top edge, wherein the top edge includes a top front edge that extends above a top rear edge, wherein the top front edge is adjacent to the front face, wherein the top rear edge is adjacent to the rear face, wherein the top front edge is perpendicular to the front face, wherein the top rear edge is perpendicular to the rear face, a bottom edge, wherein the bottom edge includes a bottom front edge that extends below a bottom middle edge and a bottom rear edge, further wherein the bottom rear edge extends below the bottom middle edge, wherein the bottom front edge is adjacent to the front face, wherein the bottom rear edge is adjacent to the rear face, wherein the bottom front edge is perpendicular to the front face, wherein bottom rear edge is perpendicular to the rear face; positioning the bottom edge of the second panel atop the top edge of the first panel such that the bottom rear edge and the bottom middle edge of the second panel abut the top front edge and the top rear edge, respectively, of the first panel; and mounting the second panel to the structure.
 5. The method of claim 4, wherein the first panel includes a front face including a fastener notch that receives fasteners; and wherein the step of positioning the bottom edge of the second panel comprises the step of positioning the bottom edge of the second panel atop the top edge of the first panel such that the bottom rear edge and the bottom middle edge of the second panel abut the top front edge and the top rear edge, respectively, of the first panel and the bottom front edge of the second panel covers the fastener notch of the first panel.
 6. The method of claim 5, wherein the second panel includes a front face including a fastener notch.
 7. The method of claim 4, wherein each of the first and second panels includes a rear face including a plurality of laterally spanning notches.
 8. The method of claim 4, wherein each of the first and second panels includes a rear face including a plurality of cut-outs.
 9. A method of installing siding on a structure, comprising the steps of: providing a first panel of the siding including: a top edge, wherein the top edge includes a top front edge that extends above a top rear edge, wherein the top front edge is adjacent to the front face, wherein the top rear edge is adjacent to the rear face, wherein the top front edge is perpendicular to the front face, wherein the top rear edge is perpendicular to the rear face, a bottom edge, wherein the bottom edge includes a bottom front edge that extends below a bottom middle edge and a bottom rear edge, further wherein the bottom rear edge extends below the bottom middle edge, wherein the bottom front edge is adjacent to the front face, wherein the bottom rear edge is adjacent to the rear face, wherein the bottom front edge is perpendicular to the front face, wherein bottom rear edge is perpendicular to the rear face; mounting the first panel to the structure; providing a second panel of the siding including: a top edge, wherein the top edge includes a top front edge that extends above a top rear edge, wherein the top front edge is adjacent to the front face, wherein the top rear edge is adjacent to the rear face, wherein the top front edge is perpendicular to the front face, wherein the top rear edge is perpendicular to the rear face, a bottom edge, wherein the bottom edge includes a bottom front edge that extends below a bottom middle edge and a bottom rear edge, further wherein the bottom rear edge extends below the bottom middle edge, wherein the bottom front edge is adjacent to the front face, wherein the bottom rear edge is adjacent to the rear face, wherein the bottom front edge is perpendicular to the front face, wherein bottom rear edge is perpendicular to the rear face; positioning the bottom edge of the second panel atop the top edge of the first panel such that the bottom rear edge and the bottom middle edge of the second panel abut the top front edge and the top rear edge, respectively, of the first panel; and mounting the second panel to the structure.
 10. The method of claim 9, wherein each of the top front edges and the bottom middle edges of each of the first and second panels includes an angled surface.
 11. The method of claim 9, wherein each of the top front edges and the bottom middle edges of each of the first and second panels includes a curved surface.
 12. An interlocking panel for siding comprising: a front face including a fastener notch; a rear face; a top edge, wherein the top edge includes a top front edge that extends above a top rear edge, wherein the top front edge is adjacent to the front face, wherein the top rear edge is adjacent to the rear face, wherein the top front edge is perpendicular to the front face, wherein the top rear edge is perpendicular to the rear face, wherein a width of the top edge is equivalent to the sum of a width of the top front edge and a width of the top rear edge; and a lower edge, wherein the lower edge includes a bottom front edge that extends below a bottom middle edge and a bottom rear edge, further wherein the bottom rear edge extends below the bottom middle edge, wherein the bottom front edge is adjacent to the front face, wherein the bottom rear edge is adjacent to the rear face, wherein the bottom front edge is perpendicular to the front face, wherein bottom rear edge is perpendicular to the rear face, wherein the bottom middle edge is perpendicular to the rear face and located at a centerline of the lower edge, wherein a width of the lower edge is equivalent to the sum of a width of the bottom front edge, a width of the bottom middle edge, and a width of the bottom rear edge, wherein the bottom middle edge is the same width as the top front edge and the bottom rear edge is the same width as the top rear edge.
 13. The panel of claim 12, wherein each of the top front edge and the bottom middle edge includes an angled surface.
 14. The panel of claim 12, wherein each of the top front edge and the bottom middle edge includes a curved surface.
 15. The panel of claim 12, wherein the panel interlocks with a starter strip such that the bottom front edge of the panel covers a fastener notch of the starter strip.
 16. The panel of claim 12, wherein the panel interlocks with a further panel such that the bottom front edge of the panel covers a fastener notch of the further panel.
 17. The panel of claim 12, wherein the rear face includes a plurality of laterally spanning notches.
 18. The panel of claim 12, wherein the rear face includes a plurality of cut-outs. 